Package including an overcap having an integral compartment for a secondary product

ABSTRACT

A package including a container with a dispensing actuator for carrying and dispensing a primary product also includes an overcap for carrying a secondary product. The overcap includes a primary cap having an upper chamber and a lower chamber. The lower chamber is adapted to releasably attach to the container and cover the dispensing actuator. The upper chamber is adapted to contain the secondary product. The overcap also includes a secondary cap for covering the upper chamber and the secondary product.

BACKGROUND

1. Technical Field

The present invention relates generally to a package including an overcap.

2. Background Art

A container with a dispensing actuator such as, as for example, an aerosol canister with a dispensing valve or a container with a pump type dispenser, is frequently packaged with an overcap over the dispensing actuator. The purpose of the overcap is mainly to protect the dispensing actuator from accidental damage prior to use by an end user. Because of its limited purpose, the overcap is only snap-fitted to the container rather than having a more secure attachment mechanism such as threads or some other mechanical locking mechanism. A drawback to this packaging system is that although the overcap is desirable, it does not provide any additional apparent value to the consumer because the consumer is likely interested only in the product contained within the container. Therefore, for containers with overcaps, it would be desirable to provide some additional value to the package with the overcap that is apparent to a consumer.

One method to add value to the overcap is to adapt the overcap to carry a secondary product that is usable by the consumer. For example, Korich U.S. Pat. No. 4,141,445 discloses a shaving cream canister with an overcap adapted to carry a razor and refill blade cartridges for the razor.

Gring U.S. Pat. No. 4,089,609 discloses a canister with a dispensing actuator for containing a shave preparation and an applicator snap-fit over and around the dispensing actuator. The applicator includes an upper compartment that holds a sponge or brush that can be used to apply the shave preparation in the canister. A separate overcap that snap fits to the canister is used to cover both the applicator and the dispensing actuator.

Mason U.S. Pat. No. 5,361,918 discloses an overcap for a nursing bottle having a nipple. The overcap has an upper compartment and a lower compartment, and snap fits on the bottle so that the nipple is covered by the lower compartment. The upper compartment is adapted to contain baby formula, and has an opening designed to facilitate easing pouring of baby formula from the upper compartment into the baby bottle. A cap is provided to cover the opening.

SUMMARY OF THE INVENTION

According to one aspect of the invention, an overcap for at least partly covering a container with a dispensing actuator includes a primary cap and a secondary cap. The primary overcap includes a sidewall defining an upper chamber with an open end and a lower chamber and a dividing wall completely spanning the sidewall between the upper chamber and the lower chamber. An opening through the sidewall adjacent to the open end provides access into the upper chamber. The sidewall is releasably attachable to the container with the lower chamber adapted for covering the dispensing actuator. The secondary overcap removably covers the open end and the access opening.

According to another aspect of the invention, a package containing a shave preparation product and a cosmetic product includes a container with a dispensing actuator and an overcap releasably connected to the container. The overcap includes a primary cap and a secondary cap. The primary cap has an upper chamber with an opening and a lower chamber. The lower chamber encloses the actuator, and the secondary cap is slidably mated around the primary cap covering the upper chamber opening. The shave preparation product is contained within the container, and the upper chamber contains the cosmetic product.

Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded isometric view of a container and an overcap for the container that is adapted to carry a secondary product;

FIG. 2 is a fragmentary cross sectional view of the assembled container and overcap taken generally along the line 2-2 of FIG. 1;

FIG. 3 is an exploded isometric view of a container and another overcap adapted to carry another secondary product;

FIG. 4 is a fragmentary cross sectional view of the assembled container and overcap taken generally along the line 4-4 of FIG. 3;

FIG. 5 is an exploded isometric view of a container and yet another overcap adapted to carry yet another secondary product; and

FIG. 6 is a fragmentary cross sectional view of the assembled container and overcap taken generally along the line 6-6 of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIGS. 1 and 2, a package 20 for a primary product 22 and a secondary product 24 includes a container 26 having a dispensing actuator 28 and an overcap 30. The package 20 has an assembled position shown in FIG. 2, and a disassembled position is shown in FIG. 1. The primary product 22 is contained within the container 26, and the secondary product 24 is carried by the overcap 30. The primary product 22 shown in the FIGS. is a shave preparation; however, the product could be any substance amenable to being stored within the container 26 and dispensed from the container through the dispensing actuator 28. The secondary product 24 shown in FIGS. 1 and 2 is a cosmetic product such as aftershave having a fragrance, skin astringent, under-arm deodorant, hand or face lotion, or any other cosmetic product suitable for containment within the overcap 30.

The container 26 is a canister having a substantially circular cylindrical sidewall 32, a can dome 34 connected to the sidewall at a double seam—or top chime—36, and a valve cup 38 located in the center of the dome for carrying the dispensing actuator 28. The container 26 may be made of any suitable material, such as metal and/or plastic, in any appropriate method. The dispensing actuator 28 includes a valve 40 with a valve stem 42 connected to a valve actuator 44 for dispensing the primary product 22 contained within the container 26 in a manner well known in the art. A valve cover 46 is attached to the container 26 and covers the can dome 34, the valve 40, and the valve stem 42, while providing access to the valve actuator 44. (The actuator 28, valve actuator 44, and valve cover 46 are shown only in schematic form in FIGS. 2 and 3.) Although the container 26 shown and described herein is a typical pressurized aerosol type canister and dispensing valve, the container could alternatively be a non-pressurized container with a different dispensing actuator such as, for example, a pump type dispenser. The container 26 could also have other shapes.

The overcap 30 includes a primary cap 48 having an upper chamber 50 for carrying the secondary product 24 and a lower chamber 52 for covering the dispensing actuator 28. The overcap 30 also includes a secondary cap—or dust cover—54 for covering the upper chamber. The overcap 30 is preferably made of a molded plastic polymer, but may be made of any suitable material. The exterior shape of the overcap 30 is preferably—although not necessarily—substantially similar to the exterior shape of the container 26 such that the entire package has a relatively smooth outer profile extending from the container sidewall 26 to the secondary cap 54 in the assembled position. The smooth outer profile of the package 20 has the advantage that the package 20 uses less space and is easier to crate together with other similar packages because there are no extraneous protrusions that could catch or bind.

The primary cap 48 includes a cylindrical sidewall 56 of circular cross section having an upper open end 58 adjacent to the upper chamber 50 and a lower open end 60 opposite the upper open end and adjacent to the lower chamber 52. The upper open end 58 provides access into the upper chamber 50 and the secondary product 24 contained within the upper chamber, and the lower open end 60 of the sidewall 56 fits around the top chime 36. A snap-fit attachment structure 62, such as, for example, a slight undercut around the inner periphery of the sidewall 56 adjacent to the lower open end 60, releasably holds the primary cap 48 to the top chime with the lower open end substantially flush with the sidewall 32 when the package 20 is in the assembled position. A substantially flat dividing wall 64 spans the sidewall 56 spaced between the upper open end 58 and the lower open end 60. The dividing wall 64 separates the upper chamber 50 located above the dividing wall from the lower chamber 52 located below the dividing wall. The dividing wall 64 is spaced a distance from the lower open end 60 sufficient to prevent the dividing wall from contacting the dispensing actuator 28 when the primary cap 48 is in the assembled position on the container 26. The sidewall 56 includes an upper portion 66 adjacent to the upper open end 58 and a lower portion 68. The outside diameter of the upper sidewall portion 66 is less than the outside diameter of the lower sidewall portion 68 such that the outer peripheral surface of the upper sidewall portion is radially inset from the outer peripheral surface of the lower sidewall portion forming a stepped shoulder 70 extending around the entire outer periphery of the sidewall 56 between the upper sidewall portion and the lower sidewall portion. The upper sidewall portion 56 extends from the open end 58 to the shoulder 70 and has a substantially smooth outer peripheral surface. The inside diameter of the upper sidewall portion 66, shown in FIG. 2 is also less than the inside diameter of the lower sidewall portion 58, but the inner diameter of the upper and lower sidewall portions may alternatively be the same (such as depicted in FIG. 4). The dividing wall 64 shown in FIGS. 1 and 2 is substantially flat and generally coplanar with the shoulder 70, but the dividing wall could have other shapes and locations as long as it separates the upper chamber 50 from the lower chamber 52 and does not engage the dispensing actuator 28 in the assembled position.

The secondary cap 54 includes a substantially cylindrical sidewall 72 having an open end 74 and an end wall 76 spanning the sidewall 72 opposite the open end 74. The end wall 76 of the secondary cap 54 covers the upper open end 58 of the primary cap 48 with the open end 74 abutting the shoulder 70 in the assembled position. The inner peripheral surface of secondary cap sidewall 72 is also substantially smooth so as to slide freely past the outer peripheral surface of the upper sidewall portion 66 of the primary cap 48. Preferably, the upper sidewall portion 66 of the primary cap 48 has a slight interference fit with the secondary cap sidewall 72 so that the secondary cap will not disengage from the primary cap when in the assembled position without being urged by a user. Other retention mechanisms such as snap-fit detents could also be used to keep the secondary cap 54 on the primary cap 48. The end wall 76 is preferably spaced from the open end 74 a distance sufficient for the open end 74 to abut the shoulder 62 when in the assembled position. The secondary cap sidewall 72 is preferably flush with the lower sidewall portion 68 of the primary cap 48 when in the assembled position such that the secondary cap sidewall, the lower sidewall portion of the primary cap, and the sidewall 32 of the container 26 are substantially aligned with each other. Of course, the sidewalls 32, 72, and sidewall portion 68 do not have to be aligned with each other, but could be displaced or shaped to accommodate other aesthetic and functional requirements.

Although the sidewalls 56, 72 depicted in the FIGS. have a circular cylinder shape, the sidewalls could be any cross sectional shape such as, for example elliptical or polygonal, to preferably match the outer shape of the container sidewall 32. In addition, it may be preferable for the sidewalls 56, 72 to have a non-cylindrical shape, depending on the shape of the container 26 and the nature of the secondary product 24 to be carried by the overcap 30. For example, if the container sidewall 32 has a polygonal non-cylindrical cross sectional shape, then the sidewall 56 may preferably have a polygonal non-cylindrical shape to match the general outer shape of the container sidewall. Further, the shoulder 70 could alternatively be formed around only a portion of the sidewall 56 with complementary portions of the secondary cap sidewall 72 shaped to fit against the shoulder. Preferably, however, at least a portion of the sidewall end 74 abuts against the shoulder 70 of the primary cap 48 in the assembled position to act as a stop for the secondary cap 54. Also preferably, although not necessarily, if only an intermittent shoulder is provided, the sidewall 72 has an appropriate complementary shape such that the sidewall 72 fits substantially flush with the lower sidewall portion 68 in the assembled position.

To use the package 20, the user removes the overcap 30 and dispenses an amount of the shave preparation 22 from inside the container through the dispensing actuator 28. The user then uses the shave preparation 22 in a usual manner of shaving. After shaving, the user removes the secondary cap 54 from the primary cap 48 and accesses the secondary product 24 with his/her fingers or contacts the product with an applicator and applies the secondary product in an appropriate manner. An applicator 78 such as a pad, brush, sponge, or other loose application device that will fit in the upper chamber 50 when the secondary cap 54 is covering the upper end 58 may be provided for use by the user. The user then returns the package 20 to the assembled position by covering the upper open end 58 of the primary cap 48 with the secondary cap 54 and snap-fitting the primary cap to the top chime 36 of the container 26 with the dispensing actuator 28 inside the lower chamber 52. In this manner the package 20 provides a primary shave preparation and a secondary cosmetic product in a convenient single package and adds value to the overcap for the container.

Referring now to FIGS. 3 and 4, a package 100 for a primary product 102 and a secondary product 104 includes a container 106 having a dispensing actuator 108 and an overcap 110 for covering the dispensing actuator. The package 100 has an assembled position shown in FIG. 4, and FIG. 3 shows the package in a disassembled position. The primary product is a shave preparation 102 and is contained within the container 106. The secondary product is a set of applicator pads 104 that carry a cosmetic product such as one of the cosmetic products listed above. The pads 104 are preferably fibrous or woven pads impregnated or coated with the cosmetic product, but other materials such as porous sponges could be used alternatively. The pads 104 are carried within the overcap 110.

The container 106 is similar to the container 26 in that it is a canister including a cylindrical sidewall 112, a can dome 114 connected to the sidewall at a top chime 116, and a valve cup 118 in the can dome carrying the dispensing actuator 108, which is shown schematically in FIGS. 3 and 4 as a well known aerosol actuator. The overcap 110 is similar to the overcap 30 in that it includes a primary cap 120 having an upper chamber 122 for carrying the pads 104, a lower chamber 124 for covering the dispensing actuator 108, and a secondary cap 126 for covering the upper chamber 122. The primary cap includes a cylindrical sidewall 128 having an upper open end 130 adjacent to the upper chamber 122 and a lower open end 132 opposite the upper open end and adjacent to the lower chamber 124. The sidewall 128 has generally the same shape as the container sidewall 112 and is sized to fit around the top chime 116 such that the lower end 132 is substantially flush with the container sidewall when the primary cap 120 is in the assembled position. A snap-fit mechanism 136 around the inner periphery of the sidewall 128 adjacent to the lower open end 132 releasably holds the primary cap 120 to the top chime 116 of the container 106. A dividing wall 134 spans the sidewall 128 spaced between the upper open end 130 and the lower open end 132 and separates the upper chamber 122 from the lower chamber 124. The dividing wall 134 is spaced a distance from the lower end 132 sufficient to prevent the dividing wall from contacting the dispensing actuator 108 in the assembled position. The sidewall 128 includes an upper portion 138 adjacent to the upper open end 130 and a lower portion 140. The outer peripheral surface of the upper sidewall portion 138 is radially inset from the outer peripheral surface of the lower sidewall portion 140 forming a stepped shoulder 142 around the entire outer periphery of the sidewall 128 between the upper sidewall portion and lower sidewall portion. An access opening 144 through the upper sidewall portion 138 is located adjacent to the upper end 130. The access opening 144 provides access to the peripheral edge of pads 104 within the upper chamber 122 so that a user may readily access the edges of the pads with a finger or other device to remove the pads from the upper chamber.

The secondary cap 126 includes a cylindrical sidewall 146 having an open end 148 and an end wall 150 spanning the sidewall opposite the open end. In the assembled position, the end wall 150 of the secondary cap 126 covers the open end 130 of the primary cap 120, and the sidewall 146 covers the access opening 144. The secondary cap sidewall 146 fits snugly around the upper sidewall portion 138 of the primary cap 110 with the open end 148 abutting the peripheral shoulder 122. The outer peripheral surface of each of the secondary cap sidewall 146, the primary cap lower sidewall portion 140, and the container sidewall 106 are preferably aligned flush with each other in order to provide a substantially smooth outer surface to the entire package 100. The outer peripheral surface of the upper sidewall portion 138 and the inner peripheral surface of the secondary cap sidewall 146 that engages the upper sidewall portion 138 are substantially smooth with a slight interference fit therebetween in order to allow the secondary cap 126 to be slidably mounted over the upper chamber 122 and require a small force to remove the secondary cap 126 from the primary cap 120.

Referring now to FIGS. 5 and 6, a package 200 for a primary product 202 and a secondary product 204 includes a container 206 and an overcap 208 similar to the overcap 30. The container 206 is a low-pressure canister or bottle having a circular cylindrical sidewall 210, a top end wall 212 attached to the sidewall at a top seam 214, and a dispensing actuator 216, which is shown schematically in FIGS. 5 & 6 as a pump mechanism, protruding above the top end wall. The overcap 208 includes a primary cap 218 having an upper chamber 220 for carrying the secondary product 204 and a lower chamber 222 for covering the dispensing actuator 216 and a secondary cap 224 for covering the upper chamber 220. The package 200 has an assembled position shown in FIG. 6, and FIG. 5 shows the package in a disassembled position. In the assembled position, the secondary cap 224 covers the upper chamber 220 and secondary product 204 and the lower chamber 222 of the primary cap 218 covers the dispensing actuator 216.

The primary cap 218 includes a cylindrical sidewall 226 having a lower open end 228 adjacent to the lower chamber 222 and an upper open end 230 opposite the lower open end and adjacent to the upper chamber 220. The sidewall 226 has generally the same shape as the container sidewall 210 and is sized to fit around the top seam 214. An undercut 232 extending around the inner periphery of the sidewall 226 adjacent to the lower end 228 snap-fits around the top seam 214 in the assembled position. A dividing wall 234 spans the sidewall 226 between the upper end 230 and lower end 228 and separates the upper chamber 220 from the lower chamber 222. A stepped shoulder 236 extending around the outer periphery of the sidewall 226 divides the sidewall into an upper sidewall portion 238 adjacent to the upper open end 230 and a lower sidewall portion 240. The outside diameter of the upper sidewall portion is less than the outside diameter of the lower sidewall portion 240.

The secondary cap 224 includes a cylindrical sidewall 242 with a similar cross section as the primary cap sidewall 226 and has an open end 244 and an end wall 246 spanning the sidewall opposite the end 244. In the assembled position, the end wall 246 of the secondary cap 224 fits over the open end 230 of the primary cap 218, and the inner surface of the secondary cap sidewall 242 mates against the outer surface of the upper sidewall portion 238 with a slight friction fit. The opposing mating surfaces of the secondary cap sidewall 242 and the upper sidewall portion 238 are substantially smooth, except for a snap-fit retention mechanism 248 such as a complementary rib and undercut, so that the secondary cap 224 slidably fits over and around the upper sidewall portion 238 of the primary cap 218. In the assembled position, the open end 244 of the secondary cap 224 preferably abuts flush against the shoulder 236 with the snap-fit mechanism 248 engaged to releasably retain the secondary cap to primary cap 218.

The secondary product 204 is a stick of caked solid such as an aftershave or underarm deodorant. The term “caked solid” shall mean any material that is in non-flowable form, whether a gel or some other non-flowable form. The secondary product 204 is held in place in the upper chamber 220 with any sufficient retention structures such as hooks 250 a and/or ribs 250 b protruding from an inner surface 252 of the upper chamber 220. Alternatively or additionally, the inner surface of the upper sidewall portion 238 may be angled inwardly such as at 252 toward the open end 230 in order to retain the secondary product 204 within the upper chamber 220.

INDUSTRIAL APPLICABILITY

The overcaps 30, 110, and 208 can add value to a package including a container carrying a primary product by carrying a secondary product.

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved. 

1. An overcap for at least partly covering a container with a dispensing actuator, the overcap comprising: a primary overcap including a first sidewall defining an upper chamber with an open end and a lower chamber, a dividing wall completely spanning the first sidewall between the upper chamber and the lower chamber, and an opening through the sidewall adjacent to the open end for providing access into the upper chamber, wherein the sidewall is releasably attachable to the container with the lower chamber adapted for covering the dispensing actuator; and a secondary overcap removably covering the open end and the access opening.
 2. The overcap of claim 1, wherein the secondary overcap includes a second sidewall having an exterior surface, and wherein the exterior surface of the second sidewall is substantially similar to an exterior surface of the first sidewall of the primary overcap.
 3. The overcap of claim 3, wherein the second sidewall has an interference fit around the first sidewall.
 4. The overcap of claim 2, wherein the second sidewall snap-fits around the first sidewall.
 5. The overcap of claim 2, wherein the first and second sidewalls are substantially circular cylindrical.
 6. The overcap of claim 2, wherein the primary overcap further includes a peripheral shoulder extending between an upper portion and a lower portion of the exterior surface of the first sidewall, and wherein the second sidewall abuts the shoulder.
 7. The overcap of claim 6, wherein the exterior surface of the second sidewall is substantially flush with the lower portion of the exterior surface of the first sidewall.
 8. An overcap for at least partly covering a container with a dispensing actuator, the overcap comprising: a primary overcap including a first sidewall defining an upper chamber with an open end and a lower chamber, a dividing wall completely spanning the first sidewall between the upper chamber and the lower chamber, wherein the sidewall is releasably attachable to the container with the lower chamber adapted for covering the dispensing actuator; and a secondary overcap removably covering the open end of the primary cap; wherein the primary cap further includes detent structures in the upper chamber for retaining a caked solid therein.
 9. The overcap of claim 8, wherein the secondary overcap includes a second sidewall having an exterior surface, and wherein the exterior surface of the second sidewall is substantially similar to an exterior surface of the first sidewall of the primary overcap.
 10. The overcap of claim 9, wherein the primary overcap further includes a peripheral shoulder extending between an upper portion and a lower portion of the exterior surface of the first sidewall, and wherein the second sidewall abuts the shoulder.
 11. The overcap of claim 10, wherein the exterior surface of the second sidewall is substantially flush with the lower portion of the exterior surface of the first sidewall.
 12. The overcap of claim 11, wherein the first and second sidewalls are substantially circular cylindrical.
 13. An overcap for at least partly covering a container with a dispensing actuator, the overcap comprising: a primary overcap including a first substantially circular cylindrical sidewall defining an upper chamber with an open end and a lower chamber, a dividing wall completely spanning the first sidewall between the upper chamber and the lower chamber, a peripheral shoulder extending between an upper portion and a lower portion of a substantially smooth exterior surface of the first sidewall, wherein the first sidewall is releasably attachable to the container with the lower chamber adapted for covering the dispensing actuator; and a secondary overcap removably covering the open end of the primary cap and abutting the shoulder, wherein the secondary overcap includes a second substantially circular cylindrical sidewall having a substantially smooth exterior surface, and wherein the exterior surface of the second sidewall is substantially flush with the lower portion of the exterior surface of the first sidewall.
 14. The overcap of claim 13, wherein the second sidewall of the secondary cap has an interference fit around the upper portion of the first sidewall.
 15. A package containing a shave preparation product and a cosmetic product, the package comprising: a container with a dispensing actuator; an overcap releasably connected to the container, the overcap comprising a primary cap and a secondary cap, the primary cap having an upper chamber with an opening and a lower chamber, the lower chamber enclosing the actuator, the secondary cap slidably mated around the primary cap and covering the upper chamber opening; wherein the shave preparation product is contained within the container, and the upper chamber contains the cosmetic product.
 16. The package of claim 15, wherein the container, the primary overcap, and the secondary overcap each form a segment of a substantially smooth, cylindrical exterior surface.
 17. The package of claim 16, wherein the exterior surface is circular.
 18. The package of claim 17, wherein the primary cap snap-fits to the container.
 19. The package of claim 18, wherein the secondary cap has an interference fit around the primary cap.
 20. The package of claim 18, wherein the secondary cap snap-fits around the primary cap.
 21. The package of claim 15, and further comprising an applicator located in the upper chamber for applying the cosmetic product contained within the upper chamber.
 22. The package of claim 21, wherein the applicator is a pad.
 23. The package of claim 22, wherein the cosmetic product is carried by the pad.
 24. The package of claim 22, wherein the pad rests on the cosmetic product.
 25. The package of claim 21, and the secondary cap further comprising an access opening adjacent to the first-called opening, wherein the access opening is sized to provide manual access to an edge of the pad.
 26. The package of claim 15, wherein the cosmetic product comprises an aftershave treatment.
 27. The package of claim 15, wherein the cosmetic product comprises a skin astringent.
 28. The package of claim 15, wherein the cosmetic product comprises a skin lotion.
 29. The package of claim 15, wherein the cosmetic product comprises a deodorant.
 30. The package of claim 15, wherein the cosmetic product comprises a cake stick.
 31. The package of claim 30, and the primary overcap further comprising detents disposed within the upper chamber for retaining the cake stick therein.
 32. The package of claim 31, wherein the detents comprise hooks protruding into the cake stick.
 33. The package of claim 31, wherein the detents comprise protrusions extending from a sidewall of the upper chamber into the cake stick.
 34. The package of claim 33, wherein the protrusions comprise ridges.
 35. The package of claim 31, wherein the detents comprise a sidewall of the upper chamber having an inwardly tapered portion extending toward the first-called opening.
 36. The package of claim 15, wherein the dispensing actuator comprises an aerosol valve.
 37. The package of claim 15, wherein the dispensing actuator comprises a pump.
 38. The package of claim 21, wherein the applicator comprises a brush.
 39. The package of claim 21, wherein the applicator comprises a sponge. 